Compliant diaphragm medical sensor and technique for using the same
United States Patent 7574244
A sensor assembly is provided that includes a frame having a loop structure. An emitter and detector are disposed on opposite sides of the loop structure. A coating is provided over the frame. The coating includes at least one diaphragm structure disposed such that at least one of the emitter and detector can move along an axis running between the emitter and detector. The sensor may thereby be placed on a patient's finger, toe, and so forth to obtain pulse oximetry or other physiological measurements. A sensor frame and method of manufacturing the frame are also provided.
US Patent References:
Flowmeter
Versaci et al. - October, 1968 - 3403555

METHOD OF MAKING ELECTRICAL MEMBERS
Traynor et al. - October, 1970 - 3536545

/D222454.html
Beeber - October, 1971 - D222454

/3721813.html
Condon et al. - March, 1973 - 3721813

Self-attaching probe for use in photoelectric monitoring of body extremities
Bond - November, 1978 - D250275


Inventors:
Eghbal, Darius (Oakland, CA, US)
Matlock, George L. (Pleasanton, CA, US)
Raridan Jr., William (Pleasanton, CA, US)
Coakley, Joseph (Dublin, CA, US)
Application Number:
11/495411
Publication Date:
08/11/2009
Filing Date:
07/28/2006
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Assignee:
Nellcor Puritan Bennett LLC (Boulder, CO, US)
Primary Class:
600/344
International Classes:
A61B5/1455
Field of Search:
600/322, 427/2.12, 427/2.11, 600/323, 600/310, 600/344, 427/2.1
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5891026Extended life disposable pulse oximetry sensor and method of makingApril, 1999Wang et al.
5902235Optical cerebral oximeterMay, 1999Lewis et al.
5910108Method and apparatus for improving the durability of a sensorJune, 1999Solenberger
5911690Use of a pulse oxymetry sensor deviceJune, 1999Rall
5912656Device for producing a display from monitored dataJune, 1999Tham et al.
5913819Injection molded, heat-sealed housing and half-etched lead frame for oximeter sensorJune, 1999Taylor et al.
5916154Method of enhancing performance in pulse oximetry via electrical stimulationJune, 1999Hobbs et al.
5916155Fetal sensor with securing balloons remote from opticsJune, 1999Levinson et al.
5919133Conformal wrap for pulse oximeter sensorJuly, 1999Taylor et al.
5919134Method and apparatus for demodulating signals in a pulse oximetry systemJuly, 1999Diab
5920263De-escalation of alarm priorities in medical devicesJuly, 1999Huttenhoff et al.
5921921Pulse oximeter with sigma-delta converterJuly, 1999Potratz et al.
5922607Measuring process for blood gas analysis sensorsJuly, 1999Bernreuter
5924979Medical diagnostic apparatus with sleep modeJuly, 1999Swedlow et al.
5924980Method and apparatus for adaptively reducing the level of noise in an acquired signalJuly, 1999Coetzee
5924982Oximeter sensor with user-modifiable color surfaceJuly, 1999Chin
5924985Patient probe disconnect alarmJuly, 1999Jones
5934277System for pulse oximetry SpO2 determinationAugust, 1999Mortz
5934925Patient cable connectorAugust, 1999Tobler et al.
5940182Optical filter for spectroscopic measurement and method of producing the optical filterAugust, 1999Lepper, Jr. et al.
5954644Method for ambient light subtraction in a photoplethysmographic measurement instrumentSeptember, 1999Dettling et al.
5957840Pinch device for detecting a biomedical signalSeptember, 1999Terasawa et al.
5960610Method of curving a fetal sensorOctober, 1999Levinson et al.
5961450Medical sensor with amplitude independent outputOctober, 1999Merchant et al.
5961452Positioning method for pulse oximetry fetal sensorOctober, 1999Chung et al.
5964701Patient monitoring finger ring sensorOctober, 1999Asada et al.
5971930Method and apparatus for removing artifact from physiological signalsOctober, 1999Elghazzawi
5978691Device and method for noninvasive continuous determination of blood gases, pH, hemoglobin level, and oxygen contentNovember, 1999Mills
5978693Apparatus and method for reduction of motion artifactNovember, 1999Hamilton et al.
5983120Method and apparatus for reflected imaging analysisNovember, 1999Groner et al.
5983122Apparatus and method for improved photoplethysmographic monitoring of multiple hemoglobin species using emitters having optimized center wavelengthsNovember, 1999Jarman et al.
5987343Method for storing pulse oximetry sensor characteristicsNovember, 1999Kinast
5991648Adjustable pulse oximetry sensor for pediatric useNovember, 1999Levin
5995855Pulse oximetry sensor adapterNovember, 1999Kiani et al.
5995856Non-contact optical monitoring of physiological parametersNovember, 1999Mannheimer et al.
5995859Method and apparatus for accurately measuring the saturated oxygen in arterial blood by substantially eliminating noise from the measurement signalNovember, 1999Takahashi
5997343Patient cable sensor switchDecember, 1999Mills et al.
5999834Disposable adhesive wrap for use with reusable pulse oximetry sensor and method of makingDecember, 1999Wang et al.
6002952Signal processing apparatus and methodDecember, 1999Diab et al.
6005658Intermittent measuring of arterial oxygen saturation of hemoglobinDecember, 1999Kaluza et al.
6006120Cordless Pulse oximeterDecember, 1999Levin
6011985Medical diagnostic instrument using light-to-frequency converterJanuary, 2000Athan et al.
6011986Manual and automatic probe calibrationJanuary, 2000Diab
6014576Segmented photoplethysmographic sensor with universal probe-endJanuary, 2000Raley et al.
6018673Motion compatible sensor for non-invasive optical blood analysisJanuary, 2000Chin
6018674Fast-turnoff photodiodes with switched-gain preamplifiers in photoplethysmographic measurement instrumentsJanuary, 2000Aronow
6022321Blood pulse wave detecting apparatus and motion intensity measuring apparatusFebruary, 2000Amano et al.
6023541Active optical oximeter probe adapterFebruary, 2000Merchant et al.
6026312Method and apparatus for diode laser pulse oximetry using fiber optical cablesFebruary, 2000Shemwell et al.
6026314Method and device for noninvasive measurements of concentrations of blood componentsFebruary, 2000Amerov et al.
6031603Sensor, method and device for optical blood oximetryFebruary, 2000Fine et al.
6035223Method and apparatus for determining the state of an oximetry sensorMarch, 2000Baker, Jr.
6036642Signal processing apparatus and methodMarch, 2000Diab et al.
6041247Non-invasive optical measuring sensor and measuring methodMarch, 2000Weckstrom
6044283Medical sensor with modulated encoding schemeMarch, 2000Fein et al.
6047201Infant blood oxygen monitor and SIDS warning deviceApril, 2000Jackson, III
6055447Patient CO.sub.2 MeasurementApril, 2000Weil
6061584Pulse oximetry sensorMay, 2000Lovejoy et al.
6064898Non-invasive blood component analyzerMay, 2000Aldrich
6064899Fiber optic oximeter connector with element indicating wavelength shiftMay, 2000Fein et al.
6067462Signal processing apparatus and methodMay, 2000Diab et al.
6073038Extended life disposable pulse oximetry sensorJune, 2000Wang et al.
6078829Measuring apparatus for biological informationJune, 2000Uchida
6078833Self referencing photosensorJune, 2000Hueber
6081735Signal processing apparatusJune, 2000Diab et al.
6083157Method and apparatus for the non-invasive determination of the concentration of a componentJuly, 2000Noller
6083172Method and apparatus for estimating physiological parameters using model-based adaptive filteringJuly, 2000Baker, Jr. et al.
6088607Low noise optical probeJuly, 2000Diab et al.
6094592Methods and apparatus for estimating a physiological parameter using transformsJuly, 2000Yorkey et al.
6095974Disposable fiber optic probeAugust, 2000Shemwell et al.
6104938Procedure, apparatus and detector for the determination of fractional oxygen saturationAugust, 2000Huiku et al.
6104939Method and apparatus for reflected imaging analysisAugust, 2000Groner et al.
6112107Flexible sensor with bulge enhancing contactAugust, 2000Hannula
6113541Noninvasive blood chemistry measurement method and systemSeptember, 2000Dias et al.
6115621Oximetry sensor with offset emitters and detectorSeptember, 2000Chin
6122535Method and apparatus for determining the concentration of a componentSeptember, 2000Kaestle et al.
6133994Testing device for light emittersOctober, 2000Mathews et al.
6135952Adaptive filtering of physiological signals using a modeled synthetic reference signalOctober, 2000Coetzee
6144444Apparatus and method to determine blood parametersNovember, 2000Haworth et al.
6144867Self-piercing pulse oximeter sensor assemblyNovember, 2000Walker et al.
6144868Reusable pulse oximeter probe and disposable bandage apparatusNovember, 2000Parker
6149481Extended life disposable pulse oximetry sensor and method of makingNovember, 2000Wang et al.
6151107Method of non-invasive determination of oxygen saturation in tissue in which blood is circulatingNovember, 2000Schöllermann et al.
6151516Active pulse blood constituent monitoringNovember, 2000Kiani-Azarbayjany et al.
6151518Instrument for measuring concentrations of constituent parts of bloodNovember, 2000Hayashi
6152754Circuit board based cable connectorNovember, 2000Gerhardt et al.
6154667Pulse oximeter probeNovember, 2000Miura
6157850Signal processing apparatusDecember, 2000Diab et al.
6159147Personal computer card for collection of real-time biological dataDecember, 2000Lichter
6163715Direct to digital oximeter and method for calculating oxygenation levelsDecember, 2000Larsen et al.
6165005Patient cable sensor switchDecember, 2000Mills et al.
6173196Shunt barrier in pulse oximeter sensorJanuary, 2001Delonzor et al.
6178343Pulse rate and heart rate coincidence detection for pulse oximetryJanuary, 2001Bindszus et al.
6179159Communicable disease barrier digit cover and dispensing package thereforJanuary, 2001Gurley
6181958Method and apparatus for non-invasive blood constituent monitoringJanuary, 2001Steuer et al.
6181959Detection of parasitic signals during pulsoxymetric measurementJanuary, 2001Schollermann
6184521Photodiode detector with integrated noise shieldingFebruary, 2001Coffin, IV
6188470Bioenergetic data collection apparatusFebruary, 2001Grace
6192260Methods and apparatus for examining tissue in vivo using the decay characteristics of scattered electromagnetic radiationFebruary, 2001Chance
6195575Fetal sensor which self-inflates using capillary forceFebruary, 2001Levinson
6198951Reflection photodetector and biological information measuring instrumentMarch, 2001Kosuda et al.
6206830Signal processing apparatus and methodMarch, 2001Diab
6213952Optical device for non-invasive measurement of blood related signals utilizing a finger holderApril, 2001Finarov
6217523Blood pulse wave detecting apparatus and motion intensity measuring apparatusApril, 2001Amano et al.
6222189Methods of enhancing optical signals by mechanical manipulation in non-invasive testingApril, 2001Misner et al.
6223064Microprocessor system for the simplified diagnosis of sleep apneaApril, 2001Lynn
6226539Pulse oximeter having a low power led driveMay, 2001Potratz
6226540Measuring process for blood gas analysis sensorsMay, 2001Bernreuter et al.
6229856Method and apparatus for demodulating signals in a pulse oximetry systemMay, 2001Diab
6230035Apparatus for determining concentrations of light-absorbing materials in living tissueMay, 2001Aoyagi et al.
6233470Absorption information measuring method and apparatus of scattering mediumMay, 2001Tsuchiya
6236871Absorption information measuring method and apparatus of scattering mediumMay, 2001Tsuchiya
6236872Signal processing apparatusMay, 2001Diab
6240305Method and apparatus for measuring absorption information of a scattering mediumMay, 2001Tsuchiya
6253097Noninvasive medical monitoring instrument using surface emitting laser devicesJune, 2001Aronow
6253098Disposable pulse oximeter assembly and protective cover thereforJune, 2001Walker et al.
6256523Low-noise optical probesJuly, 2001Diab
6256524Pulse oximeter sensor combined with a combination oropharyngeal airway and bite blockJuly, 2001Walker et al.
6261236Bioresonance feedback method and apparatusJuly, 2001Grimblatov
6263221Quantitative analyses of biological tissue using phase modulation spectroscopyJuly, 2001Chance et al.
6263222Signal processing apparatusJuly, 2001Diab
6263223Method for monitoring arterial oxygen saturationJuly, 2001Shepherd et al.
6266546System for noninvasive hematocrit monitoringJuly, 2001Steuer et al.
6266547Nasopharyngeal airway with reflectance pulse oximeter sensorJuly, 2001Walker et al.
6272363Pulse oximeter and sensor optimized for low saturationAugust, 2001Casciani et al.
6278522Optical filter for spectroscopic measurement and method of producing the optical filterAugust, 2001Lepper, Jr.
6280213Patient cable connectorAugust, 2001Tobler
6280381Intelligent system for noninvasive blood analyte predictionAugust, 2001Malin et al.
6285894Method and device for non-invasive in vivo determination of blood constituentsSeptember, 2001Oppelt et al.
6285895Measuring sensor for monitoring characteristics of a living tissueSeptember, 2001Ristolainen
6285896Fetal pulse oximetry sensorSeptember, 2001Tobler
6298252Oximeter sensor with encoder connected to detectorOctober, 2001Kovach et al.
6308089Limited use medical probeOctober, 2001von der Ruhr et al.
6321100Reusable pulse oximeter probe with disposable linerNovember, 2001Parker
6330468System using green light to determine parmeters of a cardiovascular systemDecember, 2001Scharf
6334065Stereo pulse oximeterDecember, 2001Al-Ali
6339715Method and apparatus for processing a physiological signalJanuary, 2002Bahr et al.
6342039Microprocessor system for the simplified diagnosis of sleep apneaJanuary, 2002Lynn
6343223Oximeter sensor with offset emitters and detector and heating deviceJanuary, 2002Chin et al.
6343224Reusable pulse oximeter probe and disposable bandage apparatusJanuary, 2002Parker
6349228Pulse oximetry sensor adapterFebruary, 2002Kiani
6351658Multiple-code oximeter calibration elementFebruary, 2002Middleman et al.
6353750Living body inspecting apparatus and noninvasive blood analyzer using the sameMarch, 2002Kimura
6356774Oximeter sensor with encoded temperature characteristicMarch, 2002Bernstein et al.
6360113Photoplethysmographic instrumentMarch, 2002Dettling
6360114Pulse oximeter probe-off detectorMarch, 2002Diab
6361501Pulse wave diagnosing deviceMarch, 2002Amano et al.
6363269Synchronized modulation/demodulation method and apparatus for frequency division multiplexed spectrophotometric systemMarch, 2002Hanna et al.
D455834Finger oximeterApril, 2002Donars et al.
6370408Medical sensor with amplitude independent outputApril, 2002Merchant et al.
6370409Positioning method for pulse oximetry fetal sensorApril, 2002Chung et al.
6371921System and method of determining whether to recalibrate a blood pressure monitorApril, 2002Caro
6374129Motion compatible sensor for non-invasive optical blood analysisApril, 2002Chin
6377829Resposable pulse oximetry sensorApril, 2002Al-Ali
6381479Pulse oximeter with improved DC and low frequency rejectionApril, 2002Norris
6381480Method and apparatus for monitoring fetal cerebral oxygenation during childbirthApril, 2002Stoddar et al.
6385471System for pulse oximetry SpO2 determinationMay, 2002Mortz
6385821Apparatus for securing an oximeter probe to a patientMay, 2002Modgil et al.
6388240Shielded optical probe and method having a longevity indicationMay, 2002Schulz
6393310Methods and systems for clinical analyte determination by visible and infrared spectroscopyMay, 2002Kuenstner
6393311Method, apparatus and system for removing motion artifacts from measurements of bodily parametersMay, 2002Edgar, Jr. et al.
6397091Manual and automatic probe calibrationMay, 2002Diab
6397092Oversampling pulse oximeterMay, 2002Norris et al.
6397093Non-invasive carboxyhemoglobin analyzerMay, 2002Aldrich
6400971Optical device for non-invasive measurement of blood-related signals and a finger holder thereforJune, 2002Finarov et al.
6400972Non-invasive method and system of optical measurements for determining the concentration of a substance in bloodJune, 2002Fine
6400973Arterial blood flow simulatorJune, 2002Winter
6402690Isolating ring sensor designJune, 2002Rhee et al.
6408198Method and system for improving photoplethysmographic analyte measurements by de-weighting motion-contaminated dataJune, 2002Hanna et al.
6411832Method of improving reproducibility of non-invasive measurementsJune, 2002Guthermann
6411833Method and apparatus for estimating physiological parameters using model-based adaptive filteringJune, 2002Baker, Jr. et al.
6421549Adaptive calibration pulsed oximetry method and deviceJuly, 2002Jacques
6430423Shunt barrier in pulse oximeter sensorAugust, 2002DeLonzor et al.
6430513Monitoring constituents of an animal organ using statistical correlationAugust, 2002Wang et al.
6430525Variable mode averagerAugust, 2002Weber
6434408Pulse oximetry method and system with improved motion correctionAugust, 2002Heckel et al.
6438396Method and apparatus for providing high contrast imagingAugust, 2002Cook
6438399Multi-wavelength frequency domain near-infrared cerebral oximeterAugust, 2002Kurth
6449501Pulse oximeter with signal sonificationSeptember, 2002Reuss
6453183Cerebral oxygenation monitorSeptember, 2002Walker
6453184Device for measuring light absorption materials in bloodSeptember, 2002Hyogo et al.
6456862Method for non-invasive spectrophotometric blood oxygenation monitoringSeptember, 2002Benni
6461305Pressure applicator devices particularly useful for non-invasive detection of medical conditionsOctober, 2002Schnall
6463310Method and circuit for storing and providing historical physiological dataOctober, 2002Swedlow et al.
6463311Plethysmograph pulse recognition processorOctober, 2002Diab
6466808Single device for both heating and temperature measurement in an oximeter sensorOctober, 2002Chin et al.
6466809Oximeter sensor having laminated housing with flat patient interface surfaceOctober, 2002Riley
6470199Elastic sock for positioning an optical probeOctober, 2002Kopotic
6470200Pacifier pulse oximeter sensorOctober, 2002Walker et al.
6480729Method for determining blood constituentsNovember, 2002Stone
6490466Interconnect circuit between non-compatible oximeter and sensorDecember, 2002Fein et al.
6493568Patient interface systemDecember, 2002Bell
6496711Pulse oximeter probeDecember, 2002Athan et al.
6498942Optoacoustic monitoring of blood oxygenationDecember, 2002Esenaliev et al.
6501974Compensation of human variability in pulse oximetryDecember, 2002Huiku
6501975Signal processing apparatus and methodDecember, 2002Diab
6505060Method and apparatus for determining pulse oximetry differential valuesJanuary, 2003Norris
6505061Pulse oximetry sensor with improved appendage cushionJanuary, 2003Larson
6505133Simultaneous signal attenuation measurements utilizing code division multiplexingJanuary, 2003Hanna et al.
6510329Detection of sensor off conditions in a pulse oximeterJanuary, 2003Heckel
6510331Switching device for multi-sensor arrayJanuary, 2003Williams et al.
6512937Multi-tier method of developing localized calibration models for non-invasive blood analyte predictionJanuary, 2003Blank et al.
6515273System for indicating the expiration of the useful operating life of a pulse oximetry sensorFebruary, 2003Al-Ali
6519484Pulse oximetry sensorFebruary, 2003Lovejoy et al.
6519486Method, apparatus and system for removing motion artifacts from measurements of bodily parametersFebruary, 2003Edgar, Jr. et al.
6519487Reusable pulse oximeter probe and disposable bandage apparatusFebruary, 2003Parker
6525386Non-protruding optoelectronic lensFebruary, 2003Mills
6526300Pulse oximeter probe-off detection systemFebruary, 2003Kiani
6526301Direct to digital oximeter and method for calculating oxygenation levelsFebruary, 2003Larsen et al.
6541756Shielded optical probe having an electrical connectorApril, 2003Schulz
6542764Pulse oximeter monitor for expressing the urgency of the patient's conditionApril, 2003Al-Ali
6546267Biological sensorApril, 2003Sugiura et al.
6553241Oximeter sensor with digital memory encoding sensor expiration dataApril, 2003Mannheimer et al.
6553242Physiological stress detector device and methodApril, 2003Sarussi
6553243Communicable disease barrier method of useApril, 2003Gurley
6554788Hematocrit sampling systemApril, 2003Hunley
6556852Earpiece with sensors to measure/monitor multiple physiological variablesApril, 2003Schulze et al.
6560470Electrical lockout photoplethysmographic measurement systemMay, 2003Pologe
6564077Method and apparatus for pulse oximetryMay, 2003Mortara
6564088Probe for localized tissue spectroscopyMay, 2003Soller et al.
6571113Oximeter sensor adapter with coding elementMay, 2003Fein et al.
6571114Medical measurement apparatusMay, 2003Koike et al.
6574491Method and apparatus for detecting a physiological parameterJune, 2003Elghazzawi
6580086Shielded optical probe and methodJune, 2003Schulz
6584336Universal/upgrading pulse oximeterJune, 2003Ali
6587703System and method for measuring absolute oxygen saturationJuly, 2003Cheng et al.
6587704Method for non-invasive optical measurements of blood parametersJuly, 2003Fine et al.
6589172Switching device for an array of multiple medical sensorsJuly, 2003Williams et al.
6591122Device and method for monitoring body fluid and electrolyte disordersJuly, 2003Schmitt
6591123Oximeter sensor with digital memory recording sensor dataJuly, 2003Fein et al.
6594511Method and apparatus for determining physiological characteristicsJuly, 2003Stone et al.
6594512Method and apparatus for estimating a physiological parameter from a physiological signalJuly, 2003Huang
6594513Method and apparatus for determining oxygen saturation of blood in body organsJuly, 2003Jobsis et al.
6597931System and method for absolute oxygen saturationJuly, 2003Cheng et al.
6597933Pulse oximetry sensor adapterJuly, 2003Kiani
6600940Oximeter sensor with digital memoryJuly, 2003Fein et al.
6606510Oximeter sensor with digital memory encoding patient dataAugust, 2003Swedlow et al.
6606511Pulse oximetry pulse indicatorAugust, 2003Ali
6606512Arrangement for the fixing of a medical-technical measuring device as well as a medical-technical measuring device involving this sort of arrangement, particularly a pulsoximeter sensorAugust, 2003Muz et al.
6609016Medical microprocessor system and method for providing a ventilation indexed oximetry valueAugust, 2003Lynn
6615064Non-invasive blood component analyzerSeptember, 2003Aldrich
6615065Multi-channel non-invasive tissue oximeterSeptember, 2003Barrett et al.
6618602Method and apparatus for simultaneously determining a patient's identification and blood oxygen saturationSeptember, 2003Levin
6622034Oximeter sensor with functional linerSeptember, 2003Gorski et al.
6628975Oximeter sensor with digital memory storing dataSeptember, 2003Fein et al.
6631281Recognition of a useful signal in a measurement signalOctober, 2003Kästle
6632181Rapid non-invasive blood pressure measuring deviceOctober, 2003Flaherty
6640116Optical spectroscopy pathlength measurement systemOctober, 2003Diab
6643530Method and apparatus for demodulating signals in a pulse oximetry systemNovember, 2003Diab
6643531Combination fingerprint and oximetry deviceNovember, 2003Katarow
6647279Hybrid optical delivery system for photoplethysmographyNovember, 2003Pologe
6647280Method and apparatus for processing a physiological signalNovember, 2003Bahr et al.
6650916Method and apparatus for providing high contrast imagingNovember, 2003Cook
6650917Signal processing apparatusNovember, 2003Diab
6650918Cepstral domain pulse oximetryNovember, 2003Terry
6654621Finger oximeter with finger grip suspension systemNovember, 2003Palatnik
6654622Device for the combined measurement of the arterial oxygen saturation and the transcutaneous CO2 partial pressure on an ear lobeNovember, 2003Eberhard et al.
6654623Interference suppression for measuring signals with periodic wanted signalsNovember, 2003Kästle
6654624Pulse oximeter probe-off detectorNovember, 2003Diab
6658277Signal processing method and device for signal-to-noise improvementDecember, 2003Wasserman
6658279Ablation and imaging catheterDecember, 2003Swanson
6662033Pulse oximeter and sensor optimized for low saturationDecember, 2003Casciani et al.
6665551Current driving system of light emitting diodeDecember, 2003Suzuki
6668182Pulse oxymetry data processingDecember, 2003Hubelbank
6668183Diode detection circuitDecember, 2003Hicks et al.
6671526Probe and apparatus for determining concentration of light-absorbing materials in living tissueDecember, 2003Aoyagi et al.
6671528Method and apparatus for non-invasive blood constituent monitoringDecember, 2003Steuer et al.
6671530Positioning method for pulse oximetry fetal sensorDecember, 2003Chung et al.
6671531Sensor wrap including foldable applicatorDecember, 2003Al-Ali
6671532Pulse oximetry sensor and dispensing methodDecember, 2003Fudge et al.
6675031Method and circuit for indicating quality and accuracy of physiological measurementsJanuary, 2004Porges et al.
6678543Optical probe and positioning wrapJanuary, 2004Diab
6681126Method and apparatus for improving the durability of a sensorJanuary, 2004Solenberger
6681128System for noninvasive hematocrit monitoringJanuary, 2004Steuer et al.
6681454Apparatus and method for securing an oximeter probe to a patientJanuary, 2004Modgil et al.
6684090Pulse oximetry data confidence indicatorJanuary, 2004Ali
6684091Reusable pulse oximeter probe and disposable bandage methodJanuary, 2004Parker
6694160Pulse oximeter sensor with widened metal stripFebruary, 2004Chin
6697653Reduced wire count voltage drop senseFebruary, 2004Hanna
6697655Low power pulse oximeterFebruary, 2004Sueppel et al.
6697656Pulse oximetry sensor compatible with multiple pulse oximetry systemsFebruary, 2004Al-Ali
6697658Low power pulse oximeterFebruary, 2004Al-Ali
RE38476Signal processing apparatusMarch, 2004Diab et al.
6699194Signal processing apparatus and methodMarch, 2004Diab
6699199Photoplethysmograph signal-to-noise line enhancementMarch, 2004Asada et al.
6701170Blind source separation of pulse oximetry signalsMarch, 2004Stetson
6702752Monitoring respiration based on plethysmographic heart rate signalMarch, 2004Dekker
6707257Ferrite stabilized LED driveMarch, 2004Norris
6708049Sensor with signature of data relating to sensorMarch, 2004Berson et al.
6709402Apparatus and method for monitoring respiration with a pulse oximeterMarch, 2004Dekker
6711424Method of optical measurement for determing various parameters of the patient's bloodMarch, 2004Fine et al.
6711425Pulse oximeter with calibration stabilizationMarch, 2004Reuss
6712762Personal computer card for collection of real-time biological dataMarch, 2004Lichter
6714803Pulse oximetry SpO2 determinationMarch, 2004Mortz
6714804Stereo pulse oximeterMarch, 2004Al-Ali
6714805Method and apparatus for noninvasively monitoring hemoglobin concentration and oxygen saturationMarch, 2004Jeon et al.
RE38492Signal processing apparatus and methodApril, 2004Diab et al.
6719686Fetal probe having an optical imaging deviceApril, 2004Coakley et al.
6719705Device and method for noninvasive continuous determination of physiologic characteristicsApril, 2004Mills
6720734Oximeter with nulled op-amp current feedbackApril, 2004Norris
6721584Method and apparatus for estimating physiological parameters using model-based adaptive filteringApril, 2004Baker, Jr. et al.
6721585Universal modular pulse oximeter probe for use with reusable and disposable patient attachment devicesApril, 2004Parker
6725074Quality indicator for measurement signals, in particular, for medical measurement signals such as those used in measuring oxygen saturationApril, 2004Kästle
6725075Resposable pulse oximetry sensorApril, 2004Al-Ali
6731962Finger oximeter with remote telecommunications capabilities and system thereforMay, 2004Katarow
6731963Device for enhancement and quality improvement of blood-related signals for use in a system for non-invasive measurements of blood-related signalsMay, 2004Finarov et al.
6731967Methods and devices for vascular plethysmography via modulation of source intensityMay, 2004Turcott
6735459Reusable pulse oximeter probe and disposable bandage apparatusMay, 2004Parker
6745060Signal processing apparatusJune, 2004Diab et al.
6745061Disposable oximetry sensorJune, 2004Hicks et al.
6748253Oversampling pulse oximeterJune, 2004Norris et al.
6748254Stacked adhesive optical sensorJune, 2004O'Neil et al.
6754515Stabilization of noisy optical sources in photoplethysmographyJune, 2004Pologe
6754516Nuisance alarm reductions in a physiological monitorJune, 2004Mannheimer
6760607Ribbon cable substrate pulse oximetry sensorJuly, 2004Al-Ali
6760609Adaptive calibration pulsed oximetry method and deviceJuly, 2004Jacques
6760610Sensor and method for measurement of physiological parametersJuly, 2004Tscupp et al.
6763255Shunt barrier in pulse oximeter sensorJuly, 2004DeLonzor et al.
6763256Pulse oximeterJuly, 2004Kimball et al.
6770028Dual-mode pulse oximeterAugust, 2004Ali et al.
6771994Pulse oximeter probe-off detection systemAugust, 2004Kiani et al.
6773397System for processing signal data representing physiological parametersAugust, 2004Kelly
6778923Reduced cross talk pulse oximeterAugust, 2004Norris et al.
6780158Signal processing method and pulse wave signal processing methodAugust, 2004Yarita
6791689Sensor assembly and method for measuring nitrogen dioxideSeptember, 2004Weckstrom et al.
6792300Low-noise optical probes for reducing light pipingSeptember, 2004Diab
6801797Pulse oximeter sensor with piece-wise functionOctober, 2004Mannheimer et al.
6801798Body-member-illuminating pressure cuff for use in optical noninvasive measurement of blood parametersOctober, 2004Geddes et al.
6801799Pulse oximeter and method of operationOctober, 2004Mendelson
6801802System and method for selecting physiological data from a plurality of physiological data sourcesOctober, 2004Sitzman et al.
6802812Noninvasive optical sensor for measuring near infrared light absorbing analytesOctober, 2004Walker et al.
6805673Monitoring mayer wave effects based on a photoplethysmographic signalOctober, 2004Dekker
6810277Method, apparatus and system for removing motion artifacts from measurements of bodily parametersOctober, 2004Edgar, Jr. et al.
6813511Low-noise optical probes for reducing ambient noiseNovember, 2004Diab
6816741Plethysmograph pulse recognition processorNovember, 2004Diab
6819950Method for noninvasive continuous determination of physiologic characteristicsNovember, 2004Mills
6822564Parallel measurement alarm processorNovember, 2004Al-Ali
6825619Feedback-controlled LED switchingNovember, 2004Norris
6826419Signal processing apparatus and methodNovember, 2004Diab et al.
6829496Blood component measurement apparatusDecember, 2004Nagai et al.
6830711Mold tool for an optoelectronic elementDecember, 2004Mills
6836679Method and apparatus for estimating physiological parameters using model-based adaptive filteringDecember, 2004Baker, Jr. et al.
6839579Temperature indicating oximetry sensorJanuary, 2005Chin
6839580Adaptive calibration for pulse oximetryJanuary, 2005Zonios et al.
6839582Pulse oximetry method and system with improved motion correctionJanuary, 2005Heckel
6839659System and method for acquiring dataJanuary, 2005Tarassenko et al.
6842635Optical deviceJanuary, 2005Parker
6845256Motion compatible sensor for non-invasive optical blood analysisJanuary, 2005Chin
6850787Signal component processorFebruary, 2005Weber et al.
6850788Physiological measurement communications adapterFebruary, 2005Al-Ali
6850789Combination SPO2/temperature measuring apparatusFebruary, 2005Schweitzer, Jr. et al.
6861639Systems and methods for indicating an amount of use of a sensorMarch, 2005Al-Ali
6863652Power conserving adaptive control system for generating signal in portable medical devicesMarch, 2005Huang et al.
6865407Calibration technique for non-invasive medical devicesMarch, 2005Kimball et al.
6879850Pulse oximeter with motion detectionApril, 2005Kimball
6882874Compensation of human variability in pulse oximetryApril, 2005Huiku
6898452Stereo pulse oximeterMay, 2005Al-Ali et al.
6909912Non-invasive perfusion monitor and system, specially configured oximeter probes, methods of using same, and covers for probesJune, 2005Melker
6912413Pulse oximeterJune, 2005Rantala et al.
6916289Pressure applicator devices particularly useful for non-invasive detection of medical conditionsJuly, 2005Schnall
6920345Optical sensor including disposable and reusable elementsJuly, 2005Al-Ali et al.
6931269Multi-domain motion estimation and plethysmographic recognition using fuzzy neural-netsAugust, 2005Terry
6934570Physiological sensor combinationAugust, 2005Kiani et al.
6941162Pulse oximetry sensor and dispensing methodSeptember, 2005Fudge et al.
6947781Vibratory venous and arterial oximetry sensorSeptember, 2005Asada et al.
6950687Isolation and communication element for a resposable pulse oximetry sensorSeptember, 2005Al-Ali
6954664Oximetry simulatorOctober, 2005Sweitzer et al.
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WO/2005/002434January, 2005HAT-BASED OXIMETER SENSOR
WO/2005/009221February, 2005DATA ACQUISITION SYSTEM FOR PULSE OXIMETERS
WO/2005/010567February, 2005LOW PROFILE FIBER OPTIC VITAL SIGNS SENSOR
WO/2005/010568February, 2005OPTICAL VITAL SIGNS MONITOR
WO/2005/020120March, 2005A SYSTEM AND METHOD FOR DETECTING SIGNAL ARTIFACTS
WO/2005/065540July, 2005NOVEL SPECIALLY CONFIGURED NASAL PULSE OXIMETER
WO/2006/104790October, 2006PULSE OXIMETRY SENSOR AND TECHNIQUE FOR USING THE SAME ON A DISTAL REGION OF A PATIENT'S DIGIT
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Primary Examiner:
Winakur, Eric F.
Assistant Examiner:
Berhanu, Etsub D.
Attorney, Agent or Firm:
Fletcher Yoder
Parent Case Data:

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No. 11/199,345 filed Aug. 8, 2005, the disclosure of which is hereby incorporated by reference in its entirety.

Claims:
What is claimed is:

1. A sensor assembly, comprising: a frame comprising a loop structure; an emitter and a detector disposed on opposing sides of the loop structure; and a coating provided over the frame, wherein the coating comprises at least one diaphragm structure disposed such that at least one of the emitter and the detector is capable of moving along an axis running between the emitter and the detector.

2. The sensor assembly of claim 1, wherein the emitter comprises a light emitting diode.

3. The sensor assembly of claim 1, wherein the detector comprises a photodetector.

4. The sensor assembly of claim 1, wherein the coating comprises a first diaphragm structure disposed about the emitter and a second diaphragm structure disposed about the detector.

5. The sensor assembly of claim 1, wherein the sensor assembly comprises at least one of a pulse oximetry sensor, a sensor for measuring a water fraction, or a combination thereof.

6. The sensor assembly of claim 1, wherein the frame comprises a single molded part.

7. The sensor assembly of claim 1, wherein the frame comprises two or more parts joined to form the frame.

8. The sensor assembly of claim 1, wherein the coating comprises a thermoplastic elastomer.

9. The sensor assembly of claim 8, wherein the thermoplastic elastomer comprises at least one of a thermoplastic polyolefin, a thermoplastic vulcanizate alloy, thermoplastic polyurethane, silicone, or a combination thereof.

10. The sensor assembly of claim 1, wherein the coating comprises a conformable material.

11. The sensor assembly of claim 1, wherein no moving parts of the frame remain exposed from the coating.

12. The sensor assembly of claim 1, wherein the sensor assembly is fluid tight.

13. The sensor assembly of claim 1, wherein the coating is chemically bonded to the frame.

14. The sensor assembly of claim 1, comprising a pulse oximeter monitor configured to receive data from the detector.

15. The sensor assembly of claim 1, comprising a multi-parameter monitor configured to receive data from the detector.

16. The sensor assembly of claim 1, comprising at least one integrated circuit device.

17. The sensor assembly of claim 1, comprising a cable comprising one or more integrated circuits.

18. The sensor assembly of claim 1, comprising an adapter cable connected to one or more signal transmission structures of the sensor assembly.

19. The sensor assembly of claim 1, wherein the loop structure biases the emitter and detector toward one another.

20. The sensor assembly of claim 1, wherein the at least one diaphragm structure is substantially symmetrical.

21. The sensor assembly of claim 1, wherein the at least one diaphragm structure is substantially round or substantially elliptical.

Description:

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to medical devices and, more particularly, to sensors used for sensing physiological parameters of a patient.

2. Description of the Related Art

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present invention, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present invention. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

In the field of medicine, doctors often desire to monitor certain physiological characteristics of their patients. Accordingly, a wide variety of devices have been developed for monitoring physiological characteristics. Such devices provide doctors and other healthcare personnel with the information they need to provide the best possible healthcare for their patients. As a result, such monitoring devices have become an indispensable part of modern medicine.

One technique for monitoring certain physiological characteristics of a patient is commonly referred to as pulse oximetry, and the devices built based upon pulse oximetry techniques are commonly referred to as pulse oximeters. Pulse oximetry may be used to measure various blood flow characteristics, such as the blood-oxygen saturation of hemoglobin in arterial blood, the volume of individual blood pulsations supplying the tissue, and/or the rate of blood pulsations corresponding to each heartbeat of a patient.

Pulse oximeters typically utilize a non-invasive sensor that is placed on or against a patient's tissue that is well perfused with blood, such as a patient's finger, toe, forehead or earlobe. The pulse oximeter sensor emits light and photoelectrically senses the absorption and/or scattering of the light after passage through the perfused tissue. The data collected by the sensor may then be used to calculate one or more of the above physiological characteristics based upon the absorption or scattering of the light. More specifically, the emitted light is typically selected to be of one or more wavelengths that are absorbed or scattered in an amount related to the presence of oxygenated versus de-oxygenated hemoglobin in the blood. The amount of light absorbed and/or scattered may then be used to estimate the amount of the oxygen in the tissue using various algorithms.

In many instances, it may be desirable to employ, for cost and/or convenience, a pulse oximeter sensor that is reusable. Such reusable sensors, however, may be uncomfortable for the patient for various reasons. For example, the materials used in their construction may not be adequately compliant or supple or the structural features may include angles or edges.

Furthermore, the reusable sensor should fit snugly enough that incidental patient motion will not dislodge or move the sensor, yet not so tight that it may interfere with pulse oximetry measurements. Such a conforming fit may be difficult to achieve over a range of patient physiologies without adjustment or excessive attention on the part of medical personnel. In addition, lack of a tight or secure fit may allow light from the environment to reach the photodetecting elements of the sensor. Such environmental light is not related to a physiological characteristic of the patient and may, therefore, introduce error into the measurements derived using data obtained with the sensor.

Reusable pulse oximeter sensors are also used repeatedly and, typically, on more than one patient. Therefore, over the life of the sensor, detritus and other bio-debris (sloughed off skin cells, dried fluids, dirt, and so forth) may accumulate on the surface of the sensor or in crevices and cavities of the sensor, after repeated uses. As a result, it may be desirable to quickly and/or routinely clean the sensor in a thorough manner. However, in sensors having a multi-part construction, as is typical in reusable pulse oximeter sensors, it may be difficult to perform such a quick and/or routine cleaning. For example, such a thorough cleaning may require disassembly of the sensor and individual cleaning of the disassembled parts or may require careful cleaning using utensils capable of reaching into cavities or crevices of the sensor. Such cleaning is labor intensive and may be impractical in a typical hospital or clinic environment.

SUMMARY

Certain aspects commensurate in scope with the originally claimed invention are set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of certain forms the invention might take and that these aspects are not intended to limit the scope of the invention. Indeed, the invention may encompass a variety of aspects that may not be set forth below.

There is provided a sensor assembly that includes: a frame comprising a loop structure; an emitter and a detector disposed on opposing sides of the loop structure; and a coating provided over the frame, wherein the coating comprises at least one diaphragm structure disposed such that at least one of the emitter and the detector can move along an axis running between the emitter and the detector.

There is also provided a frame of a sensor that includes: a loop structure, wherein the loop structure is configured to provide support to an overlying coating when present such that one or more diaphragm structures are formed by the overlying coating.

There is also provided a method for manufacturing a frame of a sensor that includes: forming a frame comprising at least one loop structure, wherein the at least one loop structure is configured to provide support to an overlying coating when present such that one or more diaphragm structures are formed by the overlying coating.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the invention may become apparent upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 illustrates a patient monitoring system coupled to a multi-parameter patient monitor and a sensor, in accordance with aspects of the present technique;

FIG. 2 illustrates a perspective view of an internal frame for use in a patient sensor, in accordance with aspects of the present technique;

FIG. 3 illustrates a perspective view of the internal frame of FIG. 2 in an open configuration, in accordance with aspects of the present technique;

FIG. 4 illustrates a perspective view of an overmolded patient sensor, in accordance with aspects of the present technique;

FIG. 5 illustrates a front view of the overmolded patient sensor of FIG. 4 taken along view line 5 - 5 ;

FIG. 6 illustrates the overmolded patient sensor of FIGS. 4 and 5 in use on a patient's finger, in accordance with aspects of the present technique;

FIG. 7 illustrates a side view of the overmolded patient sensor of FIGS. 4 and 5 in use on a patient's finger, in accordance with aspects of the present technique;

FIG. 8 illustrates a cross-section taken along section line 8 - 8 of the overmolded patient sensor depicted in FIG. 4; and

FIG. 9 illustrates a cross-section taken along section line 9 - 9 of the overmolded patient sensor depicted in FIG. 4.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

It is desirable to provide a comfortable and conformable reusable patient sensor, such as for use in pulse oximetry or other applications utilizing spectrophotometry, that is easily cleaned and that is resistant to environmental light infiltration. In accordance with some aspects of the present technique, a reusable patient sensor is provided that is overmolded to provide patient comfort and a suitably conformable fit. The overmold material provides a seal against bodily fluids, as well as water or other cleaning fluids, that allows easy cleaning without disassembly or special tools. In accordance with some aspects of the present technique, the reusable patient sensor includes one or more diaphragm regions that provide expansion and conformability about the digit of a patient, thereby facilitating secure placement of the sensor on the patient.

Prior to discussing such exemplary sensors in detail, it should be appreciated that such sensors are typically designed for use with a patient monitoring system. For example, referring now to FIG. 1, a sensor 10 according to the present invention may be used in conjunction with a patient monitor 12 . In the depicted embodiment, a cable 14 connects the sensor 10 to the patient monitor 12 . As will be appreciated by those of ordinary skill in the art, the sensor 10 and/or the cable 14 may include or incorporate one or more integrated circuit devices or electrical devices, such as a memory, processor chip, or resistor that may facilitate or enhance communication between the sensor 10 and the patient monitor 12 . Likewise the cable 14 may be an adaptor cable, with or without an integrated circuit or electrical device, for facilitating communication between the sensor 10 and various types of monitors, including older or newer versions of the patient monitor 12 or other physiological monitors. In other embodiments, the sensor 10 and the patient monitor 12 may communicate via wireless means, such as using radio, infrared, or optical signals. In such embodiments, a transmission device (not shown) may be connected to the sensor 10 to facilitate wireless transmission between the sensor 10 and the patient monitor 12 . As will be appreciated by those of ordinary skill in the art, the cable 14 (or corresponding wireless transmissions) are typically used to transmit control or timing signals from the monitor 12 to the sensor 10 and/or to transmit acquired data from the sensor 10 to the monitor 12 . In some embodiments, however, the cable 14 may be an optical fiber that allows optical signals to be conducted between the monitor 12 and the sensor 10 .

In one embodiment, the patient monitor 12 may be a suitable pulse oximeter, such as those available from Nellcor Puritan Bennett Inc. In other embodiments, the patient monitor 12 may be a monitor suitable for measuring tissue water fractions, or other body fluid related metrics, using spectrophotometric or other techniques. Furthermore, the monitor 12 may be a multi-purpose monitor suitable for performing pulse oximetry and measurement of tissue water fraction, or other combinations of physiological and/or biochemical monitoring processes, using data acquired via the sensor 10 . Furthermore, to upgrade conventional monitoring functions provided by the monitor 12 to provide additional functions, the patient monitor 12 may be coupled to a multi-parameter patient monitor 16 via a cable 18 connected to a sensor input port and/or via a cable 20 connected to a digital communication port.

The sensor 10 , in the example depicted in FIG. 1, is overmolded to provide a unitary or enclosed assembly. The sensor 10 , includes an emitter 22 and a detector 24 which may be of any suitable type. For example, the emitter 22 may be one or more light emitting diodes adapted to transmit one or more wavelengths of light, such as in the red to infrared range, and the detector 24 may be a photodetector, such as a silicon photodiode package, selected to receive light in the range emitted from the emitter 22 . In the depicted embodiment, the sensor 10 is coupled to a cable 14 that is responsible for transmitting electrical and/or optical signals to and from the emitter 22 and detector 24 of the sensor 10 . The cable 14 may be permanently coupled to the sensor 10 , or it may be removably coupled to the sensor 10 —the latter alternative being more useful and cost efficient in situations where the sensor 10 is disposable.

The sensor 10 described above is generally configured for use as a “transmission type” sensor for use in spectrophotometric applications, though in some embodiments it may instead be configured for use as a “reflectance type sensor.” Transmission type sensors include an emitter and detector that are typically placed on opposing sides of the sensor site. If the sensor site is a fingertip, for example, the sensor 10 is positioned over the patient's fingertip such that the emitter and detector lie on either side of the patient's nail bed. For example, the sensor 10 is positioned so that the emitter is located on the patient's fingernail and the detector is located opposite the emitter on the patient's finger pad. During operation, the emitter shines one or more wavelengths of light through the patient's fingertip, or other tissue, and the light received by the detector is processed to determine various physiological characteristics of the patient.

Reflectance type sensors generally operate under the same general principles as transmittance type sensors. However, reflectance type sensors include an emitter and detector that are typically placed on the same side of the sensor site. For example, a reflectance type sensor may be placed on a patient's fingertip such that the emitter and detector are positioned side-by-side. Reflectance type sensors detect light photons that are scattered back to the detector.

For pulse oximetry applications using either transmission or reflectance type sensors the oxygen saturation of the patient's arterial blood may be determined using two or more wavelengths of light, most commonly red and near infrared wavelengths. Similarly, in other applications a tissue water fraction (or other body fluid related metric) or a concentration of one or more biochemical components in an aqueous environment may be measured using two or more wavelengths of light, most commonly near infrared wavelengths between about 1,000 nm to about 2,500 nm. It should be understood that, as used herein, the term “light” may refer to one or more of infrared, visible, ultraviolet, or even X-ray electromagnetic radiation, and may also include any wavelength within the infrared, visible, ultraviolet, or X-ray spectra.

Pulse oximetry and other spectrophotometric sensors, whether transmission-type or reflectance-type, are typically placed on a patient in a location conducive to measurement of the desired physiological parameters. For example, pulse oximetry sensors are typically placed on a patient in a location that is normally perfused with arterial blood to facilitate measurement of the desired blood characteristics, such as arterial oxygen saturation measurement (SaO 2 ). Common pulse oximetry sensor sites include a patient's fingertips, toes, forehead, or earlobes. Regardless of the placement of the sensor 10 , the reliability of the pulse oximetry measurement is related to the accurate detection of transmitted light that has passed through the perfused tissue and has not been inappropriately supplemented by outside light sources or modulated by subdermal anatomic structures. Such inappropriate supplementation and/or modulation of the light transmitted by the sensor can cause variability in the resulting pulse oximetry measurements.

As noted above, the overmolded sensor 10 discussed herein may be configured for either transmission or reflectance type sensing. For simplicity, the exemplary embodiment of the sensor 10 described herein is adapted for use as a transmission-type sensor. As will be appreciated by those of ordinary skill in the art, however, such discussion is merely exemplary and is not intended to limit the scope of the present technique.

Referring now to FIG. 2, an internal frame 30 for a sensor 10 is depicted. In the depicted example, the internal frame 30 is a skeletal frame for the sensor 10 in which one portion of the frame is formed as a loop 32 . Such a skeletal frame may include different structures or regions that may or may not have similar rigidities. For example, the depicted skeletal frame includes the loop structure 32 and other structural supports 34 that define the general shape of the sensor 10 when coated, as discussed below with regard to FIGS. 3-9. In view of their structure providing function, the loop structure 32 and structural supports 34 may be constructed to be substantially rigid or semi-rigid. In addition, the loop structure 32 may act as a spring or biasing mechanism when coated, as discussed below, to bias the sensor 10 in the desired shape.

In addition, the skeletal frame may include a cable guide 36 through which a cable, such as an electrical or optical cable, may pass to connect to the electrical or optical conductors attached to the emitter 22 and/or detector 24 upon assembly. Likewise, a skeletal frame, such as the depicted internal frame 30 , may include component housings, such as the emitter housing 38 and detector housing 40 which are attached to the remainder of the skeletal frame, such as via the loop structure 32 . The loop structure 32 may be relatively flexible, allowing the emitter housing 38 and/or the detector housing 40 to move vertically (such as along an optical axis between the respective housings) relative to one another.

In embodiments where the internal frame 30 is skeletal, the various structural supports 34 , housings 38 and 40 , loop structure 32 , and other structures may define various openings and spaces around and/or between the structures of the skeletal frame. In this manner, the skeletal frame provides structural support at specific locations for a coating or overmolding. However, in regions where structural support is not provided, flexibility and freedom of motion in an overlying coating or overmolding may be possible. For example, in one implementation, the emitter housing 38 and/or the detector housing 40 may be attached to the remainder of the skeletal frame by a flexible loop structure 32 , as depicted in FIGS. 2 and 3. In such implementations, a coating 60 provided proximate to the emitter housing 38 and/or detector housing 40 may be sufficiently flexible (such as due to the elasticity and/or the thinness of the coating material in the open areas of the skeletal frame) such that the housings 38 and 40 may move independent of the remainder of the frame 30 along an optical axis between the housings 38 and 40 .

In certain embodiments, the internal frame 30 is constructed, in whole or in part, from polymeric materials, such as thermoplastics, capable of providing a suitable rigidity or semi-rigidity for the different portions of the internal frame 30 . Examples of such suitable materials include polypropylene, polyurethane, and nylon, though other polymeric materials may also be suitable. In other embodiments, the internal frame 30 is constructed, in whole or in part, from other suitably rigid or semi-rigid materials that provide the desired support and flexibility, such as stainless steel, aluminum, magnesium, graphite, fiberglass, or other metals, alloys, or compositions that are sufficiently ductile and/or strong. For example, metals, alloys, or compositions that are suitable for diecasting, sintering, lost wax casting, stamping and forming, and other metal or composition fabrication processes may be used to construct the internal frame 30 .

In addition, the internal frame 30 may be constructed as an integral structure or as a composite structure. For example, in one embodiment, the internal frame 30 may be constructed as a single piece from a single material or from different materials. Alternatively, the internal frame 30 may be constructed or assembled from two or more parts that are separately formed. In such embodiments, the different parts may be formed from the same or different materials. For example, in implementations where different parts are formed from different materials, each part may be constructed from a material having suitable mechanical and/or chemical properties for that part. For example, the loop structure 32 may be formed to be more flexible than the structural support 34 of the frame 30 . The different parts may then be joined or fitted together to form the internal frame 30 .

In addition, the internal frame 30 may be molded, formed, or constructed in a different configuration than the final sensor configuration. For example, the internal frame 30 for use in the sensor 10 may be initially formed, from one or more pieces, in a generally open, or flat, configuration (as depicted in FIG. 3) compared to the relatively closed configuration of the internal frame 30 when folded to form the sensor 10 (as depicted in FIG. 2). In such embodiments, a top portion 46 and a bottom portion 48 of the internal frame 30 may be formed such that they are generally open or planar and are joined by a connective portion 50 .

In such an implementation, the top portion 46 , bottom portion 48 , and connective portion 50 may be molded or formed as a single piece in an open configuration. In such an embodiment, the connective portion 50 may be broken or deformed to bring the top portion 46 and bottom portion 48 into a closed configuration, as depicted in FIG. 2. In this implementation, the top portion 46 and bottom portion 48 may be secured together, such as via a snap fitting process in which complementary connectors 52 (as depicted in FIG. 3) are snapped together to form a mechanical connection. Alternatively, the top portion 46 and bottom portion 48 may be secured together via other techniques suitable for attaching the respective portions of the internal frame 30 , such as ultrasonic welding, or heat staking or by application of an adhesive or mechanical fastener.

Alternatively, the internal frame 30 may be formed as multiple parts that are joined together to form the internal frame 30 . For example, the top portion 46 and the bottom portion 48 may be molded or formed separately and subsequently secured together to form the internal frame 30 . The different parts of the internal frame 30 may be joined together using one or more of the techniques noted above, such as a snap fitting process, ultrasonic welding, or heat staking or by application of an adhesive or mechanical fastener. If the internal frame 30 is secured together in an open configuration, the connective portion 50 may be broken or deformed to bring the top portion 46 and bottom portion 48 into a closed configuration, as depicted in FIG. 2. Alternatively, the internal frame 30 may be constructed in a closed configuration from the separately molded or formed parts, such as the top portion 46 and bottom portion 48 .

As noted above, in certain embodiments of the present technique, the frame 30 (such as a skeletal internal frame) is coated to form a unitary or integral sensor assembly as depicted in FIGS. 3-9. Such overmolded embodiments may result in a sensor assembly in which the internal frame 30 is completely or substantially coated. In embodiments in which the internal frame 30 is formed or molded as a relatively open or flat structure, the overmolding or coating process may be performed prior to or subsequent to bending the internal frame 30 into the closed configuration.

For example, the sensor 10 may be formed by an injection molding process. In one example of such a process the internal frame 30 may be positioned within a die or mold of the desired shape for the sensor 10 . A molten or otherwise unset overmold material may then be injected into the die or mold. For example, in one implementation, a molten thermoplastic elastomer at between about 400° F. to about 450° F. is injected into the mold. The overmold material may then be set, such as by cooling for one or more minutes or by chemical treatment, to form the sensor body about the internal frame 30 . In certain embodiments, other sensor components, such as the emitter 22 and/or detector 24 , may be attached or inserted into their respective housings or positions on the overmolded sensor body.

Alternatively, the optical components (such as emitter 22 and detector 24 ) and/or conductive structures (such as wires or flex circuits) may be placed on the internal frame 30 prior to overmolding. The internal frame 30 and associated components may then be positioned within a die or mold and overmolded, as previously described. To protect the emitter 22 , detector 24 , and or other electrical components, conventional techniques for protecting such components from excessive temperatures may be employed. For example, the emitter 22 and/or the detector 24 may include an associated clear window, such as a plastic or crystal window, in contact with the mold to prevent coating from being applied over the window. In one embodiment, the material in contact with such windows may be composed of a material, such as beryllium copper, which prevents the heat of the injection molding process from being conveyed through the window to the optical components. For example, in one embodiment, a beryllium copper material initially at about 40° F. is contacted with the windows associated with the emitter 22 and/or detector 24 to prevent coating of the windows and heat transfer to the respective optical components. As will be appreciated by those of ordinary skill in the art, the injection molding process described herein is merely one technique by which the frame 30 may be coated to form a sensor body, with or without associated sensing components. Other techniques which may be employed include, but are not limited to, dipping the frame 30 into a molten or otherwise unset coating material to coat the frame 30 or spraying the frame 30 with a molten or otherwise unset coating material to coat the frame 30 . In such implementations, the coating material may be subsequently set, such as by cooling or chemical means, to form the coating. Such alternative techniques, to the extent that they may involve high temperatures, may include thermally protecting whatever optical components are present, such as by using beryllium copper or other suitable materials to prevent heat transfer through the windows associated with the optical components, as discussed above.

By such techniques, the frame 30 , as well as the optical components and associated circuitry where desired, may be encased in a coating material 60 to form an integral or unitary assembly with no exposed or external moving parts of the internal frame 30 . For example, as depicted in FIGS. 4 and 5, the sensor 10 includes features of the underlying internal frame 30 that are now completely or partially overmolded, such as the overmolded external cable guide 62 and optical component housings, such as overmolded emitter housing 64 and detector housing 66 . In addition, the overmolded sensor 10 includes an overmolded upper portion 68 and lower portion 70 that may be fitted about the finger 72 (as depicted in FIGS. 6 and 7) or to the toe or other appendage of the patient as appropriate.

In one implementation, the overmolding or coating 60 is a thermoplastic elastomer or other conformable coating or material. In such embodiments, the thermoplastic elastomer may include compositions such as thermoplastic polyolefins, thermoplastic vulcanizate alloys, thermoplastic polyurethane, silicone, and so forth.

In one embodiment, the overmolding material is a thermoplastic elastomer having a durometer of about 15 to about 25 Shore. As will be appreciated by those of ordinary skill in the art, the overmolding composition may vary, depending on the varying degrees of flexibility, conformability, durability, wettability, or other physical and/or chemical traits that are desired. Furthermore, the coating material 60 may be selected based on the desired closing force imparted by the coating 60 to the upper portion 68 and lower portion 70 of the overmolded sensor body.

Furthermore, the coating material 60 may be selected based upon the desirability of a chemical bond between the internal frame 30 and the coating material 60 . Such a chemical bond may be desirable for durability of the resulting overmolded sensor 10 . For example, to prevent separation of the coating 60 from the internal frame 30 , the material used to form the coating 60 may be selected such that the coating 60 bonds with some or all of the internal frame 30 during the overmolding process. In such embodiments, the coating 60 and the portions of the internal frame 30 to which the coating 60 is bonded are not separable, i.e., they form one continuous and generally inseparable structure.

Furthermore, in embodiments in which the coating 60 employed is liquid or fluid tight, such a sensor 10 may be easily maintained, cleaned, and/or disinfected by immersing the sensor into a disinfectant or cleaning solution or by rinsing the sensor 10 off, such as under running water. In particular, such an overmolded sensor assembly may be generally or substantially free of crevices, gaps, junctions or other surface irregularities typically associated with a multi-part construction which may normally allow the accumulation of biological detritus or residue. Such an absence of crevices and other irregularities may further facilitate the cleaning and care of the sensor 10 .

Turning now to FIGS. 8 and 9, cross-sections of the coated sensor assembly 10 are depicted taken through transverse optical planes, represented by section lines 8 and 9 of FIG. 4 respectively. FIGS. 8 and 9 depict, among other aspects of the sensor 10 , the overmolding material 60 as well as underlying portions of the internal frame 30 , such as the emitter housing 38 and detector housing 40 , along with the respective emitter 22 , detector 24 , and signal transmission structures (such as wiring or other structures for conducting electrical or optical signals). In the depicted embodiment, the emitter 22 and detector 24 are provided substantially flush with the patient facing surfaces of the sensor 10 , as may be suitable for pulse oximetry applications. For other physiological monitoring applications, such as applications measuring tissue water fraction or other body fluid related metrics, other configurations may be desirable. For example, in such fluid measurement applications it may be desirable to provide one or both of the emitter 22 and detector 24 recessed relative to the patient facing surfaces of the sensor 10 . Such modifications may be accomplished by proper configuration or design of a mold or die used in overmolding the internal frame 30 and/or by proper design of the emitter housing 38 or detector housing 40 of the internal frame 30 .

In addition, as depicted in FIGS. 8 and 9, in certain embodiments portions of the coating material 60 may be flexible, such as thin or membranous regions of coating material 60 disposed about regions of the frame 30 and sensor 10 intended to flex. For example, in the depicted example, the overmolded detector housing 66 and emitter housing 64 are surrounded by comparatively thin and flexible dished regions that form diaphragm structures 76 . In the depicted embodiment, opposing, co-axial diaphragm structures 76 are provided on both the top portion 68 and bottom portion 70 of the overmolded sensor 10 . In addition, the diaphragm structures 76 may be symmetrical, such as round or elliptical structures. Such diaphragm structures 76 allow a greater range of digit sizes to be accommodated for a given retention or clamping force of the sensor 10 . For example, the diaphragm structures 76 may allow the emitter 22 and/or detector 24 , to flex or expand apart from one another along the optical axis in embodiments in which the respective housings 38 and 40 are flexibly attached to the remainder of the frame 30 . In this manner, the sensor 10 may accommodate differently sized digits. For instance, for a relatively small digit, the diaphragm structures 76 may not be substantially deformed or vertically displaced, and therefore the emitter 22 and/or detector 24 are not substantially displaced either. For larger digits, however, the diaphragm structures 76 may be deformed or displaced to a greater extent to accommodate the digit, thereby displacing the emitter 22 and/or detector 24 as well. In addition, for medium to large digits, the diaphragm structures 76 may also increase retention of the sensor 10 on the digit by increasing the surface area to which the retaining force is applied.

Furthermore, as the diaphragm structures 76 deform, the force applied to the digit is spread out over a large area on the digit due to the deformation of the diaphragm structures 76 . In this way, a lower pressure on digits of all sizes may be provided for a given vertical force. Therefore, a suitable conforming fit may be obtained in which the emitter 22 and detector 24 are maintained in contact with the digit without the application of concentrated and/or undesirable amounts of force, thereby improving blood flow through the digit.

In one embodiment, the loop structure 32 of the frame 30 and/or the coating material 60 bias the top portion 68 and a bottom portion 70 of the overmolded sensor 10 closed. An opposing force, however, may be applied to the lateral sides 78 of the overmolded sensor 10 to overcome the closing force and move the top portion 68 and bottom portion 70 apart. Alternately (or in addition), an opposing force may be applied to the inward facing surfaces 80 of the top portion 68 and bottom portion 70 to overcome the closing force and move the top portion 68 and bottom portion 70 apart. For example, in the depicted embodiment, the lateral sides 78 may be pinched or squeezed together to overcome the closing force provided by the frame 30 and the coating material 60 such that the top portion 68 and bottom portion 70 are separated. This process may be facilitated (or replaced) by the application of an opposing force to the inward facing surfaces 80 of the top portion 68 and bottom portion 70 , such as by the insertion of a finger, to separate the top portion 68 and bottom portion 70 . In this way, a patient sensor 10 incorporating the internal frame 30 may be opened for placement on a patient's finger, toe, or other appendage.

In the example depicted in FIGS. 8 and 9, the lateral sides 78 of the overmolding material facilitate the exclusion of environmental or ambient light from the interior of the sensor 10 . In this manner, the lateral sides 78 help prevent or reduce the detection of light from the outside environment, which may be inappropriately detected by the sensor 10 as correlating to the SaO 2 . Thus, a pulse oximetry sensor may detect differences in signal modulations unrelated to the underlying SaO 2 level. In turn, this may impact the detected red-to-infrared modulation ratio and, consequently, the measured blood oxygen saturation (SpO 2 ) value. The conformability of the fit of sensor 10 and the lateral sides 78 , therefore, may help prevent or reduce such errors.

Though the preceding examples relate to embodiments having two opposing diaphragm structures 76 provided on opposing faces of the sensor 10 , other embodiments are also presently contemplated. For example, in one alternative embodiment, a single diaphragm structure 76 is provided on either the top portion 68 or bottom portion 70 , with the opposing portion being relatively rigid compared to the diaphragm containing portion. In such an embodiment, the diaphragm containing portion flexes in response to opposing lateral force, as discussed above, to provide a conforming and comfortable fit when applied to a patient.

While the exemplary medical sensors 10 discussed herein are some examples of overmolded or coated medical devices, other such devices are also contemplated and fall within the scope of the present disclosure. For example, other medical sensors and/or contacts applied externally to a patient may be advantageously applied using an overmolded sensor body as discussed herein. Examples of such sensors or contacts may include glucose monitors or other sensors or contacts that are generally held adjacent to the skin of a patient such that a conformable and comfortable fit is desired. Similarly, and as noted above, devices for measuring tissue water fraction or other body fluid related metrics may utilize a sensor as described herein. Likewise, other spectrophotometric applications where a probe is attached to a patient may utilize a sensor as described herein.

While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. Indeed, the present techniques may not only be applied to transmission type sensors for use in pulse oximetry, but also to retroflective and other sensor designs as well. Likewise, the present techniques are not limited to use on fingers and toes but may also be applied to placement on other body parts such as in embodiments configured for use on the ears or nose.





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